Modular CT scanning system

ABSTRACT

The present application discloses an X-ray scanner having an X-ray source arranged to emit X-rays from source points through an imaging volume. The scanner may further include an array of X-ray detectors which may be arranged around the imaging volume and may be arranged to output detector signals in response to the detection of X-rays. The scanner may further include a conveyor arranged to convey an object through the imaging volume in a scan direction, and may also include at least one processor arranged to process the detector signals to produce an image data set defining an image of the object. The image may have a resolution in the scan direction that is at least 90% as high as in one direction, and in some cases two directions, orthogonal to the scan direction.

CROSS-REFERENCE

The present application is a continuation application of U.S. patentapplication Ser. No. 16/192,112, entitled “X-Ray Scanning Systems withStationary X-Ray Sources”, filed on Nov. 15, 2018, and issued as U.S.Pat. No. 10,901,112 on Jan. 26, 2021, which is a continuationapplication of U.S. patent application Ser. No. 15/439,837, entitled“X-Ray Scanners Having Source Points with Less Than a PredefinedVariation in Brightness”, filed on Feb. 22, 20217, and issued as U.S.Pat. No. 10,175,381 on Jan. 8, 2019, which is a continuation applicationof U.S. patent application Ser. No. 14/641,777, entitled “X-RayScanners”, filed on Mar. 9, 2015, and issued as U.S. Pat. No. 9,618,648on Apr. 11, 2017, which is a continuation of U.S. patent applicationSer. No. 13/548,873, of the same title, filed on Jul. 13, 2012, andissued as U.S. Pat. No. 9,020,095 on Apr. 28, 215, which, in turn, is acontinuation application of U.S. patent application Ser. No. 12/712,476,of the same title, filed on Feb. 25, 2010, and issued as U.S. Pat. No.8,243,876 on Aug. 14, 2012 (the “'476 application”).

The '476 application relies on U.S. Patent Provisional Application No.61/155,572 filed on Feb. 26, 2009. The '476 application also relies onGreat Britain Patent No. GB0903198.0, filed on Feb. 25, 2009, forforeign priority.

The '476 application relates to U.S. patent application Ser. No.12/485,897, filed on Jun. 16, 2009, which is a continuation of U.S.patent application Ser. No. 10/554,656, filed on Oct. 25, 2005, which isa 371 national stage application of PCT/GB04/01729, which was filed onand relies on for priority UK Patent Application No. 0309387, filed onApr. 25, 2003.

The '476 application also relates to U.S. patent application Ser. No.12/371,853, filed on Feb. 16, 2009, which is a continuation of U.S.patent application Ser. No. 10/554,975, filed on Oct. 25, 2005, which isa national stage application of PCT/GB2004/01741, filed on Apr. 23, 2004and which, in turn, relies on Great Britain Application Number0309383.8, filed on Apr. 25, 2003, for priority.

The '476 application also relates to U.S. patent application Ser. No.12/651,479, which is a continuation of U.S. patent application Ser. No.10/554,654, filed on Oct. 25, 2005, which is a national stageapplication of PCT/GB2004/001731, filed on Apr. 23, 2004, which relieson Great Britain Patent Application Number 0309371.3, filed on Apr. 25,2003 for priority.

The '476 application also relates to U.S. patent application Ser. No.12/364,067, which is a continuation of U.S. patent application Ser. No.12/033,035, which is a continuation of U.S. patent application Ser. No.10/554,569, filed on Oct. 25, 2005, which is a national stage filing ofPCT/GB04/001732, having a priority date of Apr. 25, 2003.

The '476 application also relates to U.S. patent application Ser. No.12/211,219, filed on Sep. 16, 2008, which is a continuation of U.S.patent Ser. No. 10/554,655, which is a national stage application ofPCT/GB2004/001751, filed on Apr. 23, 2004, having a priority date ofApr. 25, 2003.

The '476 application also relates to U.S. patent application Ser. No.10/554,570, which is a national stage application of PCT/GB2004/001747,filed on Apr. 23, 2004, having a priority date of Apr. 25, 2003.

The '476 application also relates to U.S. patent application Ser. No.12/097,422, filed on Jun. 13, 2008, which is a national stageapplication of PCT/GB2006/004684, filed on Dec. 15, 2006 and relies onGreat Britain Patent Application Number 0525593.0, filed on Dec. 16,2005, for priority.

Each of the aforementioned PCT, foreign, and U.S. applications is hereinincorporated by reference in their entirety.

FIELD OF THE INVENTION

The present invention relates to X-rays scanners and scanner systems. Ithas particular application in scanner systems for scanning baggage andcargo, but can also be used in other types of X-ray scanner.

BACKGROUND OF THE INVENTION

In typical computed tomography systems, X-rays, generated by an X-raysource, are collimated to form a fan beam that is transmitted through animaged object to an X-ray detector array orientated within the imagingplane. The detector array is comprised of detector elements which eachmeasure the intensity of transmitted radiation along a ray projectedfrom the X-ray source to that particular detector element. The X-raysource and detector array are typically rotated on a gantry within theimaging plane, around the imaged object, so that the fan beam interceptsthe imaged object at different angles. At each angle, a projection isacquired comprised of the intensity signals from each of detectorelements. The gantry is then rotated to a new angle and the process isrepeated to collect a number of projections at different angles to forma tomographic projection set. In alternate tomography systems, thedetector array remains fixed and comprises a 360 degree ring ofdetectors and the source is moved arcwise around the imaged objectthrough 180 degrees plus the fan beam angle or more of arc. In suchsystems, only the X-ray source is rotated to acquire the tomographicprojection set.

The time and expense of a tomographic study increases with the number ofslices required. The time required to collect the data for a series ofslices depends in part on aspects such as a) the time required toaccelerate the gantry to scanning speed, b) the time required to obtaina complete tomographic projection set, c) the time required todecelerate the gantry and d) the time required to reposition the objectin the z-axis for the next slice. Reducing the time required to obtain afull slice series may be accomplished by reducing the time required tocomplete any of these four steps. Additionally, movement of the objectunder inspection as well as the motion of the X-ray source and/ordetector array, using the gantry, results in creation of unacceptablyhigh levels of artefact in reconstructed images.

Accordingly, there is need in the prior art to reduce the overall timeof conducting a tomographic inspection. There is also need to improvethe overall imaging quality of tomographic inspection by addressingcauses leading to image artefacts—particularly those induced by physicalmotion of the source-detector assembly.

SUMMARY OF THE INVENTION

It is an object of the present invention to provide an X-ray scannercomprising an X-ray source arranged to emit X-rays from a plurality ofsource points through an imaging volume. The scanner may furthercomprise an array of X-ray detectors which may be arranged around theimaging volume and may be arranged to output detector signals inresponse to the detection of X-rays. The scanner may further comprise aconveyor arranged to convey an object through the imaging volume in ascan direction, and may also comprise at least one processor arranged toprocess the detector signals to produce an image data set defining animage of the object. The image may be a two dimensional image or a threedimensional image. The image may have a resolution in the scan directionthat is at least 90% as high as in one direction, and in some cases twodirections, orthogonal to the scan direction. For a three dimensionalimage the resolution in the scan direction may be at least 90% as high,or may be as high in the scan direction as the average of theresolutions in two other orthogonal directions. In some embodiments theresolution in the scan direction may be higher, for example at least 20%or in some cases 50% higher, than the resolution in one, or two, otherorthogonal directions. The image may have a resolution in at least twodirections, the scan direction (R1) and a direction orthogonal to thescan direction (R2). In some embodiments of the present invention,R1≥(0.90)*R2. In some cases R1≥R2.

The resolution in the scan direction may be substantially equal to theresolution in the other two directions. For example the resolutions mayall be within 10% of each other, and preferably within 5% of each other.

The source points may be arranged in a plane perpendicular to the scandirection. The detectors of the array may be located in a plane which isperpendicular to the scan direction, or a plurality of such planes.

The detector array may be offset from the source points in the scandirection. The detector array may be at least two detectors wide in thescan direction, and may for example be up to six or eight detectorswide, or in some cases up to ten detectors wide in the scan direction.The detectors may be arranged in a plurality of rings, the rings beingin respective planes, which may be spaced from each other in the scandirection. In this case there may be ten rings or less, or in some caseseight rings or less, or even six rings or less. The detectors may have awidth in a circumferential direction and each detector may be offset inthe circumferential direction from one adjacent to it in the scandirection. Each detector may have a width in the circumferentialdirection and the offset is less than the width.

The scanner may further comprise a controller arranged to activate eachof the source points in a predetermined sequence, once in each of asequence of scan cycles. The controller may be arranged to control thefrequency of the scan cycles so that it takes an integer number, whichmay be greater than one, of scan periods for the object to move adistance in the scan direction equal to the spacing of the detectors inthe scan direction.

The scan cycle frequency may be variable so that the resolution in thescan direction can be adjusted. The control means may be arranged toadjust the scan frequency so as to provide a constant resolution in thescan direction for a plurality of object speeds.

The conveyor may be arranged to convey the object at a speed of at least0.1 m/s, or at least 0.5 m/s, or at least 1.0 m/s. The scanner may bearranged to generate an image data set having a signal to noise ratio ofat least 60, or at least 80, or at least 100. The image may be made upof voxels having a size in the scan direction of 5 mm or less, or 4 mmor less, or 3 mm or less, or 2 mm or less, or 1.1 mm or less. The imagevoxels may have a size in the two directions orthogonal to the scandirection which is 5 mm or less, or 4 mm or less, or 3 mm or less, or 2mm or less, or 1.1 mm or less.

Some embodiments of the invention can provide a motionless X-ray imagingsystem able to generate reconstructed three-dimensional X-ray imageswith a conveyor speed of 0.25 m/s to 1.0 m/s, corresponding to athroughput of 800 to 3000 items per hour, for scanned objects of length1 m in the scan direction and spaced along the conveyor with a slotlength of 1.2 m in the scan direction, with equal spatial resolution inall dimensions (2 mm and better) with a reconstructed pixel size of 1.5mm×1.5 mm×1.5 mm or less with a reconstructed image signal-to-noiseratio of 50 or better, and typically in excess of 100, with no more thaneight rings of X-ray detectors.

The present invention further provides a mobile scanning systemcomprising a vehicle comprising a body and a scanner housed within thebody wherein the scanner comprises X-ray source means arranged togenerate X-rays from a plurality of source points, an array of X-raydetectors arranged to detect X-rays from the source points, and controlmeans arranged to activate each of the source points so as to scan animaging volume. The system may include a single conveyor extendingthrough the system. It may be split into two conveyor sections, one forin-feed and one for out-feed, but preferably has a single belt thatpasses across both sections.

The present invention further provides a modular scanner systemcomprising a scanner section, an input conveyor section comprising aconveyor arranged to convey items towards the scanner section and anoutput conveyor section comprising a conveyor arranged to move itemsaway from the scanner section, wherein at least one of the conveyorsections is detachably connected to the scanner section.

The present invention further provides an X-ray scanner systemcomprising an X-ray source arranged to emit X-rays from a plurality ofsource points through an imaging volume, an array of X-ray detectorsarranged to output detector signals in response to the detection of theX-rays, a controller arranged to activate each of the source points inturn, at least one processor arranged to process the detector signals toproduce an image data set corresponding to each of a plurality of viewsof an object, and a user interface arranged to receive a plurality ofdifferent user inputs and a display arranged to display each of theviews in response to a respective one of the inputs. The user interfacemay comprise one or more input members, such as input buttons, which canbe pressed or otherwise operated to provide the inputs. For example theuser interface may include a mouse. Alternatively it may comprise atouch screen with different areas which can be touched to provide thedifferent inputs.

The present invention further provides a scanner system comprising anX-ray source and an array of X-ray detectors defining a scanning volume,an input conveyor arranged to convey items into the scanning volume andan exit conveyor arranged to convey items away from the scanning volume,first and second input sensors arranged to detect the presence of anitem at first and second positions on the input conveyor and first andsecond exit sensors arranged to detect the presence of an item at firstand second positions on the exit conveyor, and control means arranged tocontrol activation of the X-ray source in response to signals from thesensors.

BRIEF DESCRIPTION OF THE DRAWINGS

These and other features and advantages of the present invention will beappreciated, as they become better understood by reference to thefollowing detailed description when considered in connection with theaccompanying drawings:

FIG. 1 is a transverse section through a scanner system according to anembodiment of the invention;

FIG. 2 is a longitudinal section through the scanner system of FIG. 1 ;

FIG. 3 is a table of exemplary, but not limiting, performancecharacteristics of the system of FIG. 1 ;

FIG. 4 is a table of exemplary, but not limiting, operatingcharacteristics for one mode of operation of the system of FIG. 1 ;

FIG. 5 shows a detector array in a scanner according to a furtherembodiment of the invention;

FIG. 6 shows a part of an image produced using the detector array ofFIG. 5 ;

FIG. 7 is a schematic view of a scanning system according to oneembodiment of the invention;

FIG. 8 is a schematic view of a scanning system according to oneembodiment of the invention;

FIG. 9 is a view of the system of FIG. 8 split into its constituentparts;

FIG. 10 is a front view of a user input panel of the embodiment of FIG.9 :

FIG. 11 is a longitudinal section through the system of FIG. 8 ;

FIG. 12 is a table of exemplary, but not limiting, operatingcharacteristics for one mode of operation of the system of FIG. 1 ;

FIG. 13 is a graph showing variation of reconstructed signal-to-noiseratio with respect to tube voltage for the system of FIG. 1 ;

FIG. 14 shows an embodiment of scintillation detector with photodiodeelectronics readout used in operation of the system of FIG. 1 ;

FIG. 15 shows an embodiment of collimation and radiation shieldingstructures to reduce scatter during operation of the system of FIG. 1 ;

FIG. 16 shows an embodiment of the electron gun operated in space chargelimited mode during operation of the system of FIG. 1 ; and

FIG. 17 shows an embodiment of the cooling system for controllingtemperature of detectors of the system of FIG. 1 .

DETAILED DESCRIPTION

Various modifications to the preferred embodiment, disclosed herein,will be readily apparent to those of ordinary skill in the art and thedisclosure set forth herein may be applicable to other embodiments andapplications without departing from the spirit and scope of the presentinvention and the claims hereto appended. Thus, the present invention isnot intended to be limited to the embodiments described, but is to beaccorded the broadest scope consistent with the disclosure set forthherein.

Referring to FIG. 1 , in one embodiment of the present invention, anX-ray scanner comprises one or more X-ray tubes 10 which are configuredinto a substantially circular arrangement around the scanner axiswherein each X-ray tube 10 contains an X-ray source having one or moreX-ray source points 12. The emission of X-rays from each source point 12in each of the X-ray tubes 10 is controlled by a switching circuit 14,with one independent switching circuit for each X-ray source point. Theswitching circuits for each tube 10 together form part of a controlcircuit 16 for that tube. A controller 18 controls operation of all ofthe individual switching circuits 14. The switching circuits 14 arecontrolled to fire in a pre-determined sequence such that in each of aseries of activation periods, fan-shaped beams of X-rays from one ormore active source points propagate through an object 20 which ismounted on a conveyor 22 towards the centre of the arrangement of X-raytubes 10.

Referring to FIG. 2 , the scanner further comprises an array of X-raydetectors 24 extending around the scanner axis. The detector array ismade up of a number of detector rings 26. Each ring is in a planeperpendicular to the scanner axis or a plurality of such planes. Thescanner axis is referred to as the Z-direction and the two orthogonaldirections, one horizontal and one vertical, are referred to as theX-direction and the Y-direction. The source points 12, in oneembodiment, are arranged in a plane perpendicular to the scan direction.

The X-Y plane or planes in which the X-ray tube source points 12 arelocated are offset from the planes of the X-ray detectors 24 such thatthere is an unobstructed path, except for the conveyor 22 and the object20 under inspection, from each active source point 12 to its associatedset of X-ray detectors 24. Thus, in one embodiment, the detectors 24have a width in a circumferential direction and each detector is offsetin the circumferential direction from one adjacent to it in the scandirection. Each detector has a width in the circumferential directionand the offset is less than the width, in one embodiment.

In one embodiment, the detector array 24 is at least two detectors widein the scan direction, and may for example be up to six or eightdetectors wide, or in some cases up to ten detectors wide in the scandirection. As mentioned earlier, the detectors may be arranged in aplurality of rings, the rings being in respective planes, which may bespaced from each other in the scan direction. In this case there may beten rings or less, or in some cases eight rings or less, or even sixrings or less. In alternate embodiments, the detectors may be arrangedin one or more helical arrays.

A processor 30 is arranged to receive the signals output by all of thedetectors 24 and forms an X-ray re-construction engine arranged toprocess the detector signals. As the X-ray source points 12 are switchedaccording to a pre-determined sequence, the detector signals aredigitized and transmitted to the X-ray reconstruction engine 30 whichproduces a reconstruction of the object 20 that is present in the beam.It is advantageous to select a sequence of X-ray source point activationwhich maximises the quality of the reconstructed image. Thereconstruction engine 30 produces from the detector signals one imagedata set for each activation of each source point 12. Each source pointis activate once in each of a series of scan cycles. The data sets forone cycle can be combined to generate a three dimensional image of aslice of the item, and a series of such image data sets built up as theitem moves through the scanner in the Z-direction can be built up into afull three dimensional image data set of the item. Also the data setsfrom one source point collected as the item moves through the scannercan be built up to form a two-dimensional image data set of the item.

An exemplary sequence provides X-ray emission from sources points thatrotate around the conveyor and object under inspection in a planesubstantially perpendicular to the direction of motion of the conveyorand object under inspection. For example there may be four sourcepoints, which may be equally spaced around the Z axis. Of course, otherscanning sequences may be adopted as required to optimise the imagereconstruction method.

It is generally reasonable to consider an optimization of the X-rayimaging system to the activity for which the system is to be deployed.With specific reference to X-ray screening of baggage and cargo items,it is highly advantageous to achieve equal resolution in all threedimensions. This substantially assists in the detection of materialsthat may be conformed into sheet-like structures. Further, it is highlyadvantageous to achieve this equally matched resolution at high conveyorspeeds, for example in the range 0.25 m/s to 1 m/s.

In the embodiment described with reference to FIGS. 1 and 2 , amotionless X-ray imaging system is able to generate reconstructedthree-dimensional X-ray images with a conveyor speed of 0.25 m/s to 1.0m/s, corresponding to a throughput of 800 to 3000 items per hour withequal spatial resolution in all dimensions (2 mm and better) with areconstructed pixel size of 1.5 mm×1.5 mm×1.5 mm or less with areconstructed image signal-to-noise ratio of 50 or better, and typicallyin excess of 100, with no more than eight rings of X-ray detectors.

Advantageously, an X-ray system of this type may be further optimized todeliver a spatial resolution in the scan direction (parallel to theconveyor) whose spatial resolution exceeds that of the in-plane spatialresolution (perpendicular to the plane of the conveyor). In oneembodiment, the X-ray scanner of the present invention is optimized todeliver image resolution in the scan direction that is at least 90% ashigh as in one direction, and in some cases two directions, orthogonalto the scan direction. In another embodiment, for a three dimensionalimage the resolution in the scan direction may be at least 90% as high,or may be as high in the scan direction as the average of theresolutions in two other orthogonal directions. In alternate embodimentsthe resolution in the scan direction may be higher, for example at least20% or in some cases 50% higher, than the resolution in one, or two,other orthogonal directions. Again, the resolution in the scan directionmay be substantially equal to the resolution in the other twodirections. For example the resolutions may all be within 10% of eachother, and preferably within 5% of each other in further embodiments.

X-ray image may have a resolution in at least two directions, the scandirection (R₁) and a direction orthogonal to the scan direction (R₂). Insome embodiments of the present invention, R₁≥(0.90)*R₂. In some casesR₁≥R₂.

FIG. 3 provides exemplary, but not limiting, performance characteristicsfor an X-ray scanner of the type shown in FIGS. 1 and 2 . These figuresare provided as an example of the performance of a system that has beenoptimized for the purpose of screening baggage and cargo items. In otherembodiments the tube voltage may be in the range from 100 kV to 200 kV,and preferably in the range from 150 kV and 180 kV. The tube current canbe in the range from 2 and 30 mA, but preferably in the range from 4 to25 mA, or in the range from 5 to 20 mA as in the examples shown. Thenumber of reconstruction slices per second may be at least 100, and maybe in the range from 100 to 1000, and preferably at least 200. In somecases at least 300 or at least 400 may be needed.

It shall be understood by one skilled in the art that the reconstructedimage signal-to-noise figures are affected by the design of the X-raysensor (for example by the sensor area, by the sensor detectionefficiency, by the noise of the associated readout electronics and bytiming jitter in the switching of the X-ray source points and the dataacquisition system), and that the information presented in this regardin FIG. 3 is for one particular detector configuration only.

Generally, it is understood that the in-plane reconstructed pixel sizeshall be determined based on overall acceptable data rate at the outputof the image reconstruction process and on the spatial resolution of theimaging data based on the optimised sensor configuration. A suitablereconstructed pixel size to match the system performance characteristicsas shown in FIG. 3 is in the range 1 mm to 2 mm and typically 1.2 mm×1.2mm.

It is further possible to establish suitable operating characteristicsfor operation of an X-ray imaging system with varying conveyor speed. Asdescribed in FIG. 4 , a set of exemplary, but not limiting, operatingcharacteristics for a particular system optimisation show operation ofthe system with conveyor speeds from 1 m/s to 0.125 m/s. Here, theoptimization seeks to maintain an identical spatial resolution and anassociated reconstructed pixel dimension 1.04 mm in the scan directionindependent of conveyor speed without changing the sensor configuration.This is achieved by adjusting the scan frequency, i.e. the frequency ofthe scan cycles, in proportion to the speed of the conveyor. In oneembodiment the conveyor speed is at least 0.1 m/s, or at least 0.5 m/s,or at least 1.0 m/s.

In some embodiments the tube current can be controlled so that it variesin direct proportion to the conveyor speed. This can provide a constantsignal-to-noise ratio which is independent of scan speed. For example ifthe scan speed is doubled then the tube current would be doubled, and ifthe scan speed is halved the tube current is also halved.

Such a practical optimization allows the performance of the X-ray systemto be altered dynamically based on imaging load. At times when highthroughput is required, the conveyor speed may be set to a fast speedwith a reduction in reconstructed image signal to noise ratio. At timesof low throughput, the conveyor speed may be reduced to a lower speedwith an associated improvement in reconstructed image signal-to-noiseratio.

According to an aspect of the present invention, the image quality forthe X-ray scanner of the present invention as shown in FIGS. 1 and 2 ,is optimized with respect to a set of parameters. For image qualityestimation and optimization, X-ray spectrum emitted by the X-ray sourceis propagated to an X-ray detector of suitable size, location andcomposition for detection of primary X-ray beam from the source. In oneembodiment, the X-ray detector used is a scintillation detector withphotodiode electronics readout system.

Signal-to-Noise Ratio (SNR)

For the X-ray scanner of the present invention, FIG. 12 is a tableshowing exemplary, but not limiting, operating characteristics for theX-ray source operating at 20 mA with an 800 mm diameter reconstructioncircle, an 8-ring X-ray detector array and a reconstructed scan rate of240 slices per second. It is observed from the data of FIG. 12 that thereconstructed image signal-to-noise ratio (SNR) is strongly dependent ontube voltage. The higher the tube voltage, the better the reconstructedimage signal-to-noise ratio (SNR).

FIG. 13 shows variation of reconstructed signal-to-noise ratio withrespect to tube voltage for the X-ray scanner of the present inventionwhen operated with a beam current of 20 mA and a reconstruction rate of240 frames per second with 8 detector rings for reconstructed imagediameters of 60 cm (1305), 80 cm (1310) and 120 cm (1315) each with 1mm×1 mm×1 mm reconstructed voxel dimension. Persons of ordinary skill inthe art would appreciate that a 1 mm×1 mm×1 mm voxel size suits securityinspection applications while a signal-to-noise ratio of over 100provides the level of quantitative image that is required in manypractical applications.

Accordingly the X-ray scanner of FIGS. 1 and 2 of the present inventionis optimized for signal-to-noise by aiming for a balance in cost,complexity and performance. In one embodiment, the scanner is optimizedto generate an image data set having a signal to noise ratio of at least60, or at least 80, or at least 100. The image is made up of voxelshaving a size in the scan direction of 5 mm or less, or 4 mm or less, or3 mm or less, or 2 mm or less, or 1.1 mm or less. The image voxels havea size in the two directions orthogonal to the scan direction which is 5mm or less, or 4 mm or less, or 3 mm or less, or 2 mm or less, or 1.1 mmor less.

In one embodiment the X-ray scanner of the present invention provides amotionless X-ray imaging system able to generate reconstructedthree-dimensional X-ray images with a conveyor speed of 0.25 m/s to 1.0m/s, corresponding to a throughput of 800 to 3000 items per hour withequal spatial resolution in all dimensions (2 mm and better) with areconstructed pixel size of 1.5 mm×1.5 mm×1.5 mm or less with areconstructed image signal-to-noise ratio of 50 or better, and typicallyin excess of 100, with no more than eight rings of X-ray detectors.

Contrast

Contrast in the X-ray scanner of the present invention is defined as1/SNR, where SNR is signal-to-noise ratio. Referring FIG. 12 , in oneembodiment, at 150 kVp the contrast that may be resolved in an openfield image is determined as (1/105)×100%=0.95%. The smaller this numberis the better the contrast resolution of the imaging system. Persons ofordinary skill in the art should note that contrast in a regioncontaining an object which attenuates an X-ray beam will be less than inan open field region since the number of X-ray photons that penetratethrough that region will be less than in an open field region.

Dynamic Range

Dynamic range is defined as (full-scale signal)/(dark noise). The darknoise is obtained by switching off the X-ray source while leaving thedetectors and image reconstruction system active. If this dark level isnormalized to zero and the light level (i.e. that intensity which isreconstructed with the X-ray beam switched on with no object in thebeam) is normalized to 1000, the dynamic range is equal to1000/(standard deviation in the dark image). An optimized X-ray scannerof the present invention, in one embodiment, provides a reconstructeddark noise of the order of 0.1% of full scale or less, thereby resultingin a dynamic range of 1000 or more. The overall X-ray scanner dynamicrange is dependent on the noise of the electronics readout system used.Thus, the noisier the electronics readout system, the worse the overallscanner dynamic range. Electronics readout system noise depends at leaston the design of the photodiode, on the layout and length of the signaltraces that lead from the photodiode sensors, on the design of the inputelectronics stage and on the resolution of the analogue-to-digitalconverter that follows its front end amplifier.

To achieve a wide dynamic range, the X-ray scanner of the presentinvention uses a scintillation detector 1400 with photodiode electronicsreadout as shown in FIG. 14 . In one embodiment, the individualsegmented scintillation crystals 1405 of the scintillation detector 1400are glued together with tungsten foil septa. The tungsten septa preventoptical cross-talk between individual crystals. The septa stop energeticCompton recoil and photoelectrons transferring signal between adjacentscintillation crystals to reduce cross-talk between adjacent crystals.

A reverse illuminated photodiode array 1410 with thin common cathodeentrance window is adhered, glued, or otherwise attached to the base ofthe scintillation crystal array 1405. Optical photons from thescintillator 1405 pass through a thin optical coupling, further througha thin passivation/contact layer in the photodiode and into the bulkregion of the photodiode. Charge generated in the depletion region driftunder the influence of an applied bias towards a set of anodes—one anodecontact region per scintillation crystal. The anode is advantageouslyconstructed so as to minimize cross-talk of drift electrons from onepixel to another. The photodiode array 1410 is then bump bonded to apatterned substrate 1415 using, for example, a conductive epoxy pad onan indium bump bond with backfill of adhesive to ensure good adherenceof the photodiode/crystal array to the substrate 1415.

The multi-layer ceramic substrate 1415 is advantageously drilled,printed with conductive ink and fired at high temperature to produce amulti-layer circuit card with pads on one side that match the layout ofanodes on the photodiode array 1410 and on the other side match the padson suitable electronic readout circuits 1420. The thermal expansioncoefficient of the ceramic substrate 1415 and photodiode 1410 arematched to provide good thermal stability during firing of the adhesivesand during bump bonding.

The electronic readout circuit 1420 is advantageously either soldered orfixed to the ceramic substrate 1415 using conductive epoxy pads. A lowdensity connector then takes electrical signals from the front-endelectronics to subsequent signal processing circuitry. In this way, thescintillator detector 1400 has minimum trace lengths and hence lowintrinsic capacitance which helps to maximise dynamic range of the X-rayscanner of the present invention.

Linearity

Intrinsic linearity of an X-ray system depends on aspects such asfiltering of the X-ray spectrum emitted from X-ray source, X-ray tubeoperating voltage, filtering of the X-ray beam prior to X-ray detectorsand the material from which the X-ray detector is fabricated. Also,degradation of X-ray system linearity is caused by detection of X-rayswhich have scattered from the object under investigation and on X-rayswhich scatter from the components of the X-ray system itself.

Therefore, the X-ray scanner of the present invention uses collimationand radiation shielding structures to reduce scatter. FIG. 15 shows anembodiment of the shielding system used in the X-ray scanner of FIGS. 1and 2 of the present invention. FIG. 15 shows how the first set ofcollimators 1505 shield the primary beam 1510 as it is emitted fromX-ray tube 1515 and how the second set of collimators 1520 again provideshielding before the beam 1510 reaches X-ray detectors 1525. In oneembodiment of the optimized X-ray scanner of the present invention, ascatter fraction of the order of 1% is achieved in open fieldconditions.

The X-ray scanner optimized for low scatter also results in maximizingits contrast performance. The signal-to-noise ratio (SNR) of an X-raysystem, the noise performance of which is dominated by X-ray photonnoise, is defined as:

${SNR} = {\frac{Mean}{S.D.} = {\frac{\sigma^{2}}{\sigma} = \sigma}}$

In other words, the signal-to-noise ratio (SNR) is simply the standarddeviation of the photon signal. However, in the presence of X-rayscatter, the situation is changed such that the standard deviation, σ²,comprises noise due both to the primary signal as well as due toscatter:

${SNR} = \frac{\sigma^{2}}{\sigma + \sigma_{S}}$

A scatter fraction of 1% of primary beam intensity results in areduction of SNR by a similar amount. The distribution of scatteredradiation at the detectors is approximately constant independent ofposition in the array for a given object density. Thus, the impact ofscatter is more significant in high attenuation regions of an image thanin low attenuation regions of an image.

Therefore, to maximize imaging performance, the X-ray scanner of thepresent invention further uses a well controlled space charge limitedelectron gun 1600 as shown in FIG. 16 . As described earlier withreference to FIGS. 1 and 2 , the X-ray scanner of the present inventionutilizes a plurality of individual electron sources. To minimizevariation between output source intensity of each electron gun, theX-ray scanner electron gun 1600 is operated in a space charge limitedmode. Here, the electron emitter 1620 is operated with a high electronyield but the allowable emitted signal is determined by two controllableparameters: (a) geometry and (b) extraction field. In one embodiment,the two parameters are the only two parameters used to determine theallowable emitted signal.

Referring to FIG. 16 , it is observed that with a typical cathode 1605to grid electrode 1610 distance ‘d.’ of 0.5 mm, a variation of the orderof 20 μm in this distance ‘d.’ leads to a variation in beam current ofonly a few percent. However, variation in electron gun brightness isstrongly affected by variation in the tolerance in positioning of thefilament 1615 within the cathode 1605, on the thickness of the filamentwire and on the distribution of thermal packing that may exist aroundthe filament 1615. Considering the aforementioned aspects, in oneembodiment, the X-ray scanner of the present invention is optimized toachieve less than 5% variation in brightness between individual electronemitters/sources 1620.

Thermal Load on X-Ray Tube Target

Thermal load on X-ray tube target of the X-ray scanner of the presentinvention is minimized to allow high power operation over extendedoperating periods. As a first measure, this thermal load minimization isachieved by having a large, distributed, anode where only small sectionsof the anode are irradiated by an electron beam at any one time and thattoo only for very short durations. Still, for example, a distributedanode with an irradiation time of 80 μs per source point results in anincrease in localized temperature at the central point of the electronirradiation spot by around 200 degrees. Thus, as a second measure, acoolant fluid is passed around the anode such that the coolant iscapable of extracting the total power that is driven into the anode (2.4kW for a system operating at 160 kV, 20 mA). As a result, the anode ismaintained at a temperature which is substantially constant overextended operating periods. The coolant fluid is selected to have goodthermal transfer properties and low viscosity with a high ionisationthreshold. Coolant flow rate is maintained to establish turbulent flowin the coolant pipe in order to maximise thermal transfer from the anodeinto the coolant fluid.

Thermal Load on X-Ray Detectors

Scintillation efficiency of X-ray detectors as well as leakage currentof photodiodes (when operated in reverse bias condition) of thedetectors varies with temperature. Therefore, the X-ray scanner of thepresent invention provides cooling of its X-ray detectors to maintain aconstant operating temperature independent of ambient conditions,thereby stabilizing the reconstructed voxel values resulting in highquantitative accuracy of X-ray image.

FIG. 17 shows an embodiment of the cooling system for controllingtemperature of detectors 1700 of the X-ray scanner of the presentinvention. As shown, a coolant channel 1710 is interfaced with a copperblock 1715 that has high thermal conductivity supported using mechanicalsupport 1735. Readout electronics 1725, located at the back of ceramicsubstrate 1720 is placed in a recess in the copper block 1715 and isthermally connected to the cooled copper block 1715 using a suitableheat sinking compound with high thermal conductivity. The ceramicsubstrate 1720 is then placed in direct contact with the copper block1715, again using a suitable heat sink compound to maximize thermalconnection between the ceramic substrate 1720 and the copper block 1715.Since ceramic materials, such as high density alumina, have good thermalproperties therefore the photodiode and crystal 1730 are maintained at atemperature which is close to that of the copper block 1715. The entiredetector assembly 1700 is placed within a light tight, electricallyconductive and environmentally sealed enclosure, such as one fabricatedusing carbon fibre composite materials, and includes a low densityconnector 1740. By controlling the temperature of the coolant fluidwithin a range of +1 degree, a similar level of temperature control ismaintained at the detector. This thermal control results in high levelof stability of the reconstructed image, and typically better than 0.1%.

Referring back to FIGS. 1 and 2 , in some situations, such as formaintenance or for the purposes of passing a specific regulatoryperformance requirement, it can be beneficial to constrain the switchingof the source points 12 in the X-ray system to a sequence that is suitedto other imaging methods. As an example, a single one of the sourcepoints 12 may be switched on continuously without any further sourcepoints in the scanning sequence. In this case, as the conveyor 22 scanspast the stationary X-ray fan-beam, a two-dimensional image data set isbuilt up, from which a two dimensional image can be generated.

As an enhancement of this application, the detector rings may beconfigured as shown in FIG. 5 . By way of example, a sensor with fourdetector rings 40 is shown in which the centre of the detectors 42 ineach ring is shifted by ½ of a detector spacing with reference to itsadjacent rings. Data is collected from each ring 40 of sensors after theconveyor has moved a distance equal to the width of one sensor ring inthe scan direction 45. Referring to FIG. 6 , image data from ring 1 isthen interposed with data from ring 2 after one time slice, with datafrom ring 3 after two time slices and with data from ring 4 after threetime slices and the combined data is used to provide one line of thetwo-dimensional projected image. Note that the vertical pixel samplingrate is in the two dimensional image is in this example four timesbetter than the horizontal pixel sampling rate.

An improvement in horizontal pixel sampling rate can also be achieved bysampling more rapidly with respect to the conveyor velocity than just bysampling once every one detector spacing, i.e. by performing more thanone scan cycle in the time taken for the object to move a distance equalto the width of the detector ring 40 of FIG. 5 .

In a related scanning mode, a sequence may be generated in which X-raytube source points are activated over a small range of angles, typicallyover 10 degrees, at a rate such that all of the chosen source points areactivated individually in the time taken for the conveyor to travel onedetector spacing. For a detector dimension of 5 mm, a source pointlocated every 1 degree and a conveyor speed of 0.5 m/s, each individualprojection will be collected in 1 ms. In this way, a set oftwo-dimensional projection images are acquired, one for each selectedsource point.

A graphical user interface may then be provided which enables theoperator to view each image in turn under control of a suitable inputdevice such as a mouse or a pair of buttons, and to rapidly flip betweenimages from adjacent source points as the input device is actuated. Theresult is a “rocking two-dimensional image” in which the object underinspection appears to rotate back and forth about the central axis ofthe scanning tunnel in the direction parallel to the conveyor motionunder the control of the operator. This rocking image provides apowerful method by which the operator can easily perceive depthinformation about objects within the object under inspection.

It is clear that the data for the above two scanning modes exists withinthe data set that is typically collected during data acquisition for athree-dimensional tomographic image reconstruction in the system of FIG.1 , and this two-dimensional image data can advantageously be displayedalongside the full three-dimensional data set.

A high speed three-dimensional X-ray scanning system as described withreference to FIGS. 1 and 2 can be deployed for screening baggage andcargo in these, and a number of other ways.

FIG. 7 shows a high speed 3D X-ray scanning system, such as that of FIG.1 , located in a vehicle 50 according to a further embodiment of theinvention. Due to the lack of moving parts in this X-ray system, it ispractical to locate the equipment within a vehicular platform withinwhich the equipment is subject to significant mechanical shock. Suchshock does not mechanically misalign the X-ray system which is a commonfailing of known systems.

The scanning equipment is very compact due to the lack of a mechanicalgantry to rotate the source and detector assembly as is required inknown X-ray tomography systems. The scanning equipment is of low powerconsumption compared to known mechanical X-ray tomography systems due tothe lack of motor drive components.

In this mobile configuration, the vehicle 50 includes a cab 52 and abody 54 which has two side walls 56, 58, a rear end 60 having doors 62therein, and a roof 64. Each of the side walls 56, 58 has an aperture 66in it and a scanner, such as that of FIG. 1 , is located within thevehicle body 54. One end of the conveyor is located close to one of theapertures 66 which forms an input aperture, and the other end of theconveyor is located close to the other aperture which forms an exitaperture. The X-ray scanner is advantageously located close to the backwheels 68. Side panels 70 are hingedly attached to each of the two sidewalls of the vehicle, one over each of the apertures 66, which can beopened to expose the scanning tunnel entrance and exit. Additional inputand exit conveyors 72 are provided and removably connectable to thesides of the vehicle. These conveyors can be ramped to allow baggage andcargo to be loaded into the scanner and unloaded from a safe height(typically less than 1.2 m) with some protection from the weatherafforded by the open side panels 70 which can be supported in an opencondition so as to extend over, and thereby cover, the input and exitconveyors 72.

An operator inspection workstation can be located adjacent to the driverin the cab 52 at the front of the vehicle or adjacent to the equipmentitself in the body 54 at the rear of the vehicle.

In a further embodiment of the invention, the X-ray system may beconstructed on a wheelable chassis as shown in FIGS. 8 and 9 , whereFIG. 9 is an exploded view of the chassis of FIG. 8 . Referring now toFIGS. 8 and 9 simultaneously, the chassis 80 includes lockable wheels82. When the wheels are unlocked, the system may be wheeled easily fromone location to another. When at its new location, the unit can be fixedin position by locking its wheels 82. A mains power cable 84 is used toobtain electrical power from a power outlet adjacent to the chosenscanning site.

To allow the system 80 to be moved between various levels of a building,the scanner may be easily and quickly separated into three parts: aninlet tunnel section 86, an exit tunnel section 88 and a scanner section90 as shown in FIG. 9 , to allow it to be moved from one level in thebuilding to another using an elevator. Each section is designed to beself contained and electrical connectors 92 are provided on both sidesof the scanner section 90 and on the inner end of each of the othersections 86, 88, making the system connectorized such that when thethree sections are brought together, electrical connectors on adjoiningelectrical interface plates mate to render the system functional.

To save space, in-feed and out-feed conveyor sections 94, 96 fold up toa stowed position against the front face of their respective tunnelsections 86, 88 and can be dropped back down into an in-use positiononce the system has been manoeuvered to its required location.

An operator workstation 100 is also advantageously located on one ormore of the tunnel sections 86, 88 such that the necessary computermonitor 102 and keyboard assembly 104 are arranged to fold down from theequipment itself in order to minimise cabling and to minimise down timebetween system relocation.

Referring to FIG. 10 , keyboard 104 which may be provided with thesystem, but may be used in other suitable systems, makes interactionwith the X-ray image straightforward. The image can be displayed on thecomputer monitor and manipulated by means of the keyboard 104.

In one embodiment, the keyboard 104 of FIG. 10 comprises a plurality ofdedicated view select buttons 106 each of which the operator may use tobring up a standard view of the item under inspection. Standard viewsinclude a 2D projection image, a 3D interactive image, one or morepre-rendered 3D views from standard orientations and/or a rocking 2Dimage. A second group of buttons 108 allow the operator to select from agroup of look-up tables for image colouring. Example look-up tablesinclude greyscale (black to white), inverse greyscale (white to black),pseudo colour and materials specific colours based on dual energymaterials discrimination and X-ray scatter imaging. A further group ofcontrols 110 allow the user to interact with the image data using atrackball 112 and select buttons 114 or a track-pad and select buttonsdepending on user preference. A final group of buttons 116 allow theused to mark the image as being clear following inspection, to mark theimage as being rejected following inspection, and to run an automatedsequence of image displays which show image data for the item underinspection in a standardised preset sequence of views as a mixture ofstatic 3D rendered images and one or more dynamic 3D rendered views.

Referring back to FIG. 9 , typically, a single image display monitor 102is used in order to view the X-ray image data. In some situations, asecond computer monitor may be provided in order to show informationabout a related network of X-ray systems and other data relevant to thearticle under inspection such as passenger data, manifest data,destination of the article under inspection, shipping agent and carrier.

Referring now to FIG. 11 , in this embodiment of the present invention,the X-ray system 1100 is provided with audible and visible alarms. Theuse of audible alarms is minimised to prevent excess noise in theoperating environment, however audible sounders are provided to indicateif an object has become stuck within the system. Visual alarms areprovided to indicate when the X-ray beam is turned on and when the X-raybeam is turned off. The system 1100 is provided with means to turn theX-ray beam on and off automatically depending on whether an item ispresent to be inspected or not. This is achieved simply andinexpensively through the use of sensors, such as infra-red sensors 1through 4, which are located at suitable positions along the length ofthe conveyor 120 as shown in FIG. 11 . In this case there are twosensors in each tunnel section 86, 88 located at different distancesfrom the scanner image volume. Sensors 1 and 2 are in the inlet tunnelsection 86, with sensor 1 further from the scanner, and Sensors 3 and 4are located in the exit tunnel section 88 with sensor 4 further from thescanner. When an object enters the inspection tunnel in the section 86,it breaks light beam 1. The object continues to move down the tunneluntil it reaches Sensor 2. Sensor 1 continues to measure the length ofthe bag, the length being determined at the point when the output ofSensor 1 returns to normal. When Sensor 2 sees the object, it turns onthe X-ray beam. The X-ray beam is kept on until the trailing edge of theobject passed through Sensor 3 at which point the X-ray beam will beturned off unless a second object is about to pass Sensor 2. In thiscase, the beam is kept on until the second object has been scanned.Sensor 4 assists the transfer of the object out from the X-ray system1100 to a following baggage handling system or other cargo handlingsystem. Further visual indicators warn of the status of safetyinterlocks, of electrical power and other machine parameters asappropriate.

In one embodiment, the X-ray system 1100 is also provided with a HumanMachine Interface. This comprises a video screen through which isprovided dynamic status information on the scanning process (includingthe locations of objects to be scanned within the system), statisticalinformation on the quantity and type of objects scanned together withinspection results and machine status information including software andhardware revision levels, electrical, computational, X-ray and sensorsub-system status indication. In one embodiment, the Human MachineInterface is advantageously provided with a touch screen interface, asis known to those of ordinary skill in the art, with the requirement foran operator to enter a security code in order to access some elements ofthe available information.

It will be appreciated that various above-disclosed embodiments, otherfeatures and functions, or alternatives thereof, may be desirablycombined into many other different systems or applications. Variouspresently unforeseen or unanticipated alternatives, modifications,variations, or improvements therein may be subsequently made by thoseskilled in the art which are also intended to be encompassed by thefollowing claims. In particular, it should be appreciated that these alloperative numbers represent an exemplary range and the present inventionencompasses ranges that represent improvements, including higherresolution, improved signal to noise ratio, lower voltage, and morerapid conveyor speeds, relative to the numbers shown.

I claim:
 1. A modular X-ray scanning system comprising: an inlet tunnelsection defined by an inlet tunnel housing, wherein the inlet tunnelhousing comprises a first side and a second side and wherein the secondside comprises a first electrical connector; a scanning section definedby a scanning section housing, wherein the scanning section housingcomprises a stationary computed tomography (CT) scanner configured toemit X-rays from a plurality of positions, wherein the scanning sectionhousing comprises a third side and a fourth side, wherein the third sidecomprises a second electrical connector, wherein the fourth sidecomprises a third electrical connector, and wherein the inlet tunnelsection is configured to removably attach to the scanning section suchthat, upon attachment, the first electrical connector mates to thesecond electrical connector; and an exit tunnel section defined by anexit tunnel housing, wherein the exit tunnel housing comprises a fifthside and a sixth side, wherein the fifth side comprises a fourthelectrical connector, and wherein the exit tunnel section is configuredto removably attach to the scanning section such that, upon attachment,the third electrical connector mates to the fourth electrical connector.2. The modular X-ray scanning system of claim 1, further comprising afirst conveyor adapted to attach to the first side of the inlet tunnelsection.
 3. The modular X-ray scanning system of claim 2, furtherwherein the first conveyor is configured to move from a horizontaloperational position to a vertical stowed position.
 4. The modular X-rayscanning system of claim 1, further comprising a second conveyor adaptedto attach to the sixth side of the exit tunnel section.
 5. The modularX-ray scanning system of claim 4, further wherein the second conveyor isconfigured to move from a horizontal operational position to a verticalstowed position.
 6. The modular X-ray scanning system of claim 1,further comprising an operator workstation, wherein the operatorworkstation comprises a computer monitor and keyboard.
 7. The modularX-ray scanning system of claim 6, wherein at least a portion of theoperator is configured to fold down from a surface of the inlet tunnelhousing, the scanning section housing, or the exit tunnel housing. 8.The modular X-ray scanning system of claim 6, wherein the keyboardcomprises a plurality of dedicated view select buttons.
 9. The modularX-ray scanning system of claim 8, wherein a first of the plurality ofdedicated view select buttons is adapted to generate a 2D projectionimage upon selection.
 10. The modular X-ray scanning system of claim 9,wherein a second of the plurality of dedicated view select buttons isadapted to generate a 3D interactive image upon selection.
 11. Themodular X-ray scanning system of claim 10, wherein a third of theplurality of dedicated view select buttons is adapted to generate arocking 2D projection image upon selection.
 12. The modular X-rayscanning system of claim 6, wherein the keyboard comprises a pluralityof image coloring buttons.
 13. The modular X-ray scanning system ofclaim 12, wherein a first of the image coloring buttons is adapted togenerate a greyscale image upon selection.
 14. The modular X-rayscanning system of claim 13, wherein a second of the image coloringbuttons is adapted to generate an inverse greyscale image uponselection.
 15. The modular X-ray scanning system of claim 14, wherein athird of the image coloring buttons is adapted to generate a color imagebased on dual energy material discrimination and X-ray scatter data uponselection.
 16. The modular X-ray scanning system of claim 6, wherein thekeyboard comprises a plurality of image marking buttons.
 17. The modularX-ray scanning system of claim 16, wherein a first of the plurality ofimage marking buttons is adapted to mark a generated image as beingrejected.
 18. The modular X-ray scanning system of claim 17, wherein asecond of the plurality of image marking buttons is adapted to mark agenerated image as being cleared.